Cleaning system for paint particles

ABSTRACT

The invention relates to a cleaning module for cleaning an air stream, comprising a hollow article which has an inlet port for the entry of the air stream to be cleaned and an outlet port for the exit of the cleaned air stream, and further comprising a cleaning structure for cleaning the air stream by particle separation and/or for filtration of the air stream, wherein the cleaning structure has at least two separate cleaning sub-structures which through an opening element in the hollow article can be removed from the hollow article and/or can be arranged inside said hollow article.

The present invention concerns a separation structure for cleaning an air flow in accordance with the features of the classifying portion of claim 1, a cleaning module for cleaning an air flow in accordance with the features of the classifying portion of claim 5, a set in accordance with the features of the classifying portion of claim 6 and an insertion frame in accordance with the features of the classifying portion of claim 19.

The modular arrangement of filter modules of cardboard is known from WO 03/084638 A2. They serve for the separation of paint particles or paint mist (overspray) from an exhaust air from a spray booth in which for example parts for a motor vehicle are being painted.

It is noteworthy in that respect that a very large number of various paints is used. As a result the exhaust air from spray booths contains widely varying kinds of paint impurities which for example are distinguished by particle size and moisture content. For relatively small dry particles labyrinths with small openings and severe deflection configurations have to be provided for separation purposes so that due to their inertia (or due to centrifugal force) the particles are stopped at deflecting baffle walls of the labyrinth or the separator while the cleaned air issues downstream of the filter module.

When dealing with large particle sizes with a high proportion of moisture a large amount of paint can be separated off in a cleaning module over a short time. Particularly when the cleaning modules are disposed in the floor of the spray booth that results in a heavy loading on the cleaning module which is made from cardboard and that loading is still further increased by the suction action of a fan for producing the air flow through the cleaning modules. In the case of cleaning modules in accordance with the state of the art the result of this is that the separation structures present therein collapse under their own weight when loaded with paint and no longer perform their function.

An object of the invention is to provide a separation structure, a cleaning module, an insertion frame and a set comprising a hollow body and cleaning sub-structures, which allow an enlarged range of application, that is to say which are suitable for the separation of paint particles and overspray with a greater degree of variety than is the case in the state of the art.

That object is attained by a separation structure having the features of claim 1, a cleaning module having the features of claim 5, a set having the features of claim 6 and an insertion frame having the features of claim 19.

In accordance with the invention that is achieved on the one hand by an increased stability being imparted to the separation structure by the provision of at least one stabilization wall. On the other hand that is effected by the cleaning structure having at least two mutually separate cleaning sub-structures which by way of an opening element on the hollow body can be removed from the hollow body and/or can be arranged in the hollow body. By virtue of the provision of a set in which at least two different combinations of cleaning sub-structures can be arranged in the hollow body, it is possible to achieve an even broader applicability.

In particular it can be provided that cleaning sub-structures and/or the cleaning modules are replaceable independently of each other.

Further advantageous embodiments are defined in the appendant claims.

In order to be able to remove even very fine overspray from the air flow it can be provided that the at least two cleaning sub-structures include a filter structure. Such filter structures can be of various different configurations. For example it is possible here to use a mat or a fleece of glass fibers. Preferred thicknesses of such mats or fleeces are preferably below 20 cm and particularly preferably below 10 cm. In addition it is possible to use so-called Columbus material as the filter material. That comprises paper, preferably waste paper, in which parallel and displaced slits are stamped or cut. Openings are produced by pulling transversely relative to the slits. A plurality of layers of that material can advantageously be used as the filter material.

Separation structures can also be designed in various ways. For example they can be rectangular structures in a plan view, after being unfolded. Diamond structures however are also known (for example marketed under the name “Andreae”).

Cleaning modules according to the invention can be arranged in insertion frames. Those insertion frames can extend over a wall, the top or the floor of the spray booth. The cleaning modules can be arranged in succession in those insertion frames and individually removed or replaced.

Separation structures can preferably be provided in various geometrical dimensions, in particular thicknesses.

It is also possible to provide separation structures which, in particular by virtue of the size of the openings, are optimized to the separation of particles of differing sizes. In particular the separation structures can be of such configurations that those with greater geometrical dimensions, in particular thicknesses, are optimized for the separation of larger particles, and vice-versa.

That permits accurate matching of the cleaning module to the soiling involved in the air flow (particle size, degree of moisture). That also permits selective swapping of successively arranged cleaning modules, which is advantageous as separation structures which are optimized for various particle sizes reach their capacity limit at different rates.

It is further advantageous that the selective swappability of the cleaning modules means that stockkeeping is necessary to a lesser degree.

For a good fit of the cleaning sub-structures in the hollow body it can be provided that, in a view along an axis which is substantially parallel to air flow in the condition of being arranged in the hollow body, the cleaning sub-structures have a contour which substantially corresponds to a cross-section, preferably perpendicular to the air flow, of a hollow space in the hollow body. That also ensures that no flow portion of the air flow remains uncleaned because no path leads past the cleaning sub-structures.

Particularly preferably it can be provided that at least one separation structure can be folded together. Storage and transport of the separation structures is considerably facilitated by the reduced volume.

That effect is further enhanced if it is provided that the at least one separation structure is substantially flat after being folded together.

The reinforcing action of a stabilization wall can be improved in that the separation structure is inhibited in terms of being folded together in the condition of being arranged in the hollow body, by internal walls in the hollow body.

It can preferably be provided that the at least one stabilization wall is arranged substantially centrally with respect to a direction in the plane of the baffle walls. That can optimize the strengthening action of the stabilization wall.

The at least one stabilization wall can be connected to the at least two baffle walls, wherein that is preferably the case in a foldable and/or hinged fashion. That can be easily implemented for example by way of a film hinge. That permits a very flat structure in the condition of being folded together, which in the unfolded condition enjoys a high degree of stiffness.

In addition it can preferably be provided that the at least one stabilization wall is oriented substantially parallel to the air flow. For, particularly when the cleaning module is arranged in a floor or a ceiling of a spray booth, the direction of the air flow corresponds to that direction of the main loading on the separation structure.

Quite particularly preferably it can be provided that the hollow body and/or at least one separation structure comprises cardboard, paper or card. That permits particularly simple disposal or recycling of the separation structures or the cleaning modules. It is however certainly also conceivable for separation structures and/or hollow bodies to be made from metal, plastic, wood or the like.

In a further preferred configuration it can be provided that at least one separation structure has at least two flaps which are oriented substantially parallel to the air flow and between which a further separation structure can be arranged in a hollow body. As a result it is possible for a separation structure to serve for various geometrical dimensions involved, in particular thicknesses. That means it can be used either with a separation structure between the flaps, or without. In the latter case the flaps serve as spacers relative to an internal wall of the hollow body or a further separation structure.

Further advantages and details of the invention will be apparent from the Figures and the related specific description. In the Figures:

FIG. 1a through 1h show various perspective diagrammatic views of cleaning modules according to the invention,

FIG. 2a through 2h show perspective views of a separation structure according to the invention in various folded conditions,

FIG. 3a through 3c show a further embodiment of a separation structure according to the invention in various folded conditions,

FIGS. 4a and 4b show diagrammatic views of various combination options of separation structures according to the invention in cleaning modules, and

FIG. 5a through 5e show views of possible arrangements of cleaning modules according to the invention in insertion frames.

The cleaning module 10 shown in Figure is firstly includes a hollow body 5 as well an intake opening 6 for the intake of the air flow to be cleaned. As the outlet opening is arranged on the rear of the hollow body 5 it cannot be seen in these views. The outlet opening is of a substantially similar configuration to the intake opening 6.

The hollow body 5 has opening elements 8 which are in the form of opening flaps. In the present view they are opened so that there is a clear view on to the interior of the hollow body 5. Figure is shows a plurality of cleaning sub-structures 7 which in this case are all in the form of separation structures 1. The separation structures 1 have baffle walls 2 provided with openings 3. For the sake of clarity not all baffle walls 2 and all openings 3 are provided with reference numerals as they are in part present as a multiplicity thereof.

FIG. 1b is similar to FIG. 1a except with the difference that two of the cleaning structures 7 are in the form of filter structures 9. Those filter structures 9 include glass fiber mats or fleeces but can also include Columbus material or the like.

FIG. 1c again shows the cleaning module 10 but this time with closed opening elements 8. The cleaning module can be inserted in that condition.

The opening elements 8 can also be in the form of removable covers (shoebox-like), which is shown in FIGS. 1d and 1e . Otherwise the cleaning module 10 in FIGS. 1d and 1e is similar to those in FIG. 1a through 1 c.

FIG. 1f through 1h show further embodiments, wherein the cleaning sub-structures 7 in these cases do not extend over the entire cross-sectional area (from the point of view of the air flow which is indicated by an arrow beside 1 f) of the hollow body 5.

FIG. 2a through 2h show a first embodiment of a separation structure 1 according to the invention in various folded conditions. FIG. 2a in that respect firstly shows the separation structure 1 in the delivery state. Parts of the structure are then unfolded (FIG. 2b ). The entire separation structure 1 is thereafter folded together once again, in which case the parts unfolded in FIG. 2b face towards each other.

Then the condition of the separation structure 1 is such that it can be fitted in a cleaning module 10 (FIG. 2e ). FIG. 2f corresponds to FIG. 2e , with the separation structure 1 being shown in a turned position, as indicated by arrows. After use in a cleaning module 10, for example upon disposal of the cleaning module 10, the separation structure 1 can be made substantially flat (FIG. 2h ) by a single folding operation (FIG. 2g ). That can simplify disposal thereof.

FIG. 3a through 3c show a further separation structure 1 according to the invention. That can be put into the operating condition (FIG. 3c ) from the delivery state (FIG. 3a ) by a folding operation (FIG. 3b ) which is indicated by arrows. The arrangement of the stabilization walls 4 between the baffle walls 2 can be particularly clearly seen in this embodiment. The stabilization walls 4 are arranged substantially centrally with respect to a direction in the plane of the baffle walls 2. It is also possible to see flaps 11, between which on the one hand further separation structures 1 can be arranged—to save space—and which on the other hand can function as spacers so that the separation structure 1 is firmly fitted in the cleaning module 10.

FIG. 4a and 4b diagrammatically show cleaning sub-structures 7 of various geometrical dimensions, in particular thickness, as well as various combinations of their arrangement in a cleaning module 10. In this embodiment the cleaning sub-structures 7 are provided in three different thicknesses of 100 mm, 200 mm, 300 mm or 500 mm, wherein the thicknesses are respectively noted on the cleaning sub-structures 7. Similarly there are cleaning modules 10 in various design configurations, which differ by virtue of the overall thickness of cleaning sub-structures 7 which they are capable of adopting. In this case too the various overall thicknesses of 100 mm, 200 mm, 300 mm or 500 mm are noted on the cleaning modules 10.

FIG. 4b shows some various combination options which are consecutively numbered. In the designs 1 through 6 a respective cleaning module 10 is used, which can accommodate cleaning sub-structures 7 involving an overall thickness of 500 mm. In the configurations 7 through 9 the cleaning module 10 accommodates cleaning sub-structures of an overall thickness of 300 mm. The configurations 10 and 11 concern cleaning modules 10 with a 200 mm overall thickness. Configuration 12 concerns a cleaning module with a 100 mm overall thickness. Configuration 13 concerns a cleaning module with a 500 mm overall thickness. The various possible combinations are apparent therefrom.

It is to be noted that the cleaning sub-structure 7 which is 300 mm in thickness has flaps 11. For the sake of clarity not all flaps 11 are provided with reference numerals. In that way the cleaning sub-structure 7 which is in the form of a separation structure 1 can serve as a cleaning sub-structure 7 of a thickness of 300 mm (configurations 6 and 7 in FIG. 4b ) or a thickness of 200 mm (configuration 1 in FIG. 4b ).

Cleaning modules 10 according to the invention can be arranged in succession in insertion frames 12. Here too various combinations are possible, which is shown on the one hand diagrammatically (at the left) and on the other hand as a perspective view (at the right) in FIG. 5a through 5e respectively. Preferably cleaning modules 10 which are optimized for coarser paint impurities or paint droplets are arrange facing the contaminated air flow. They can then be changed individually. Those cleaning modules which reach their capacity limit later can remain in the insertion frames 12 for longer. 

1. A separation structure for cleaning an air flow having at least two baffle walls which occur in succession in the direction of the air flow and which are provided with openings, wherein arranged between the at least two baffle walls is at least one stabilization wall oriented transversely relative to the baffle walls.
 2. A separation structure as set forth in claim 1, wherein the at least one stabilization wall is connected to the at least two baffle walls.
 3. A separation structure as set forth in claim 2, wherein the at least one stabilization wall is connected to the at least two baffle walls foldably and/or hingedly.
 4. A separation structure as set forth in claim 1, wherein the at least one stabilization wall is oriented substantially parallel to the air flow.
 5. A cleaning module for cleaning an air flow comprising a hollow body which has an intake opening for the intake of the air flow to be cleaned and an outlet opening for the outlet of the cleaned air flow, and a cleaning structure for cleaning the air flow by separation of particles and/or for filtration of the air flow, wherein the cleaning structure has at least two mutually separate cleaning sub-structures which by way of an opening element on the hollow body can be removed from the hollow body and/or can be arranged in the hollow body, wherein the at least two cleaning sub-structures preferably include at least one separation structure as set forth in claim
 1. 6. A set comprising a hollow body which has an intake opening for the intake of an air flow to be cleaned and an outlet opening for the outlet of the cleaned air flow, and a plurality of cleaning sub-structures which preferably includes at least one separation structure as set forth in claim 1, wherein at least two different combinations of cleaning sub-structures can be arranged in the hollow body.
 7. A cleaning module as set forth in claim 5, wherein the at least one separation structure has at least two baffle walls which occur in succession in the direction of the air flow and which are provided with openings.
 8. A cleaning module or set as set forth in claim 5, wherein the at least two cleaning sub-structures include a filter structure.
 9. A cleaning module or set as set forth in claim 5 wherein separation structures (1) are provided in various geometrical dimensions, in particular thicknesses (100, 200, 300).
 10. A cleaning module or set as set forth in claim 5, wherein there are provided separation structures which are optimized for the separation of particles of differing sizes, in particular by virtue of the size of the openings.
 11. A cleaning module or set as set forth in claim 5 wherein the hollow body is substantially cuboidal.
 12. A cleaning module or set as set forth in claim 5, wherein in a view along an axis which is substantially parallel to the air flow in the condition of being arranged in the hollow body the cleaning sub-structures have a contour which substantially corresponds to a cross-section, preferably perpendicular to the air flow, of a hollow space in the hollow body.
 13. A separation structure as set forth in claim 1 wherein at least one separation structure can be folded together.
 14. A separation structure, cleaning module or set as set forth in claim 13, wherein the at least one separation structure is substantially flat after being folded together.
 15. A separation structure, cleaning module or set as set forth in claim 13, wherein the separation structure is inhibited in terms of being folded together in the condition of being arranged in the hollow body by internal walls in the hollow body.
 16. A separation structure, cleaning module or set as set forth in claim 1, wherein at least one separation structure has openings which are displaced transversely relative to a direction of the air flow and/or which are different in their size along the direction of the air flow.
 17. A separation structure, cleaning module or set as set forth in claim 1, wherein the hollow body and/or at least one separation structure comprises cardboard, paper or card.
 18. A separation structure, cleaning module or set as set forth in claim 1, wherein at least one separation structure has at least two flaps which are oriented substantially parallel to the air flow and between which a further separation structure can be arranged in the hollow body.
 19. An insertion frame in which cleaning modules, in particular as set forth in claim 5, are arranged, wherein at least two cleaning modules can be arranged in succession in the direction of the air flow.
 20. A cleaning module as set forth in claim 5, wherein at least one separation structure can be folded together. 